Footwear



June 7, 193s. N.. w. MATHEY 2,120,107

FOOTWEAR Filled June 2, 1937 Patented June 7, 1938 :UNIT-ED STAT-:es

PAT-ENT 'oer-iler 9 Claims.

This invention pertains to footwear, and more especially to aV stiffener for use in the manufacture of boots-and shoes, and toa method of making such-a stiifener, and is herein illustrated in its application to a stiffener for the -toe or heel portion of a shoe upper,although not limited to this particular use.

Various materials have heretofore been prov posed from which to make toe and heel stiffeners, among them brous sheet material impregnated witha thermoplastic binder or sheet material of or including a oellulosic derivative, for example cellulose acetate, etc., but while such materials are extensively used, they are not altogether Vsatisfactory either from the standpoint of the maker or the user of the shoe. v7For instance, thermoplastic'materials require the use of heat to make them sufliciently-exible for lasting; they tend to soften when exposed for example to solar heat in the shop vwindow or by too close contact with heating apparatus, for example steam radiators during wear, and thus sag and become permanently deformed; and Vthey are usually too stiif and heavy for use in the so-called plain-toe shoes (that is, those having no toe cap). On the other hand, stiifeners comprising cellulosic derivatives must be softened-prior to lasting by the useV of an appropriate solvent, for example acetona'usually of highly inflammable character,-and, after incorporation in the shoe, are so stiff and brittle as to crush and'break when subjected to abnormal pressure.

Among the objects of the present invention is to provide a stiffener which is not brittle nor subject to sagging or deformation by exposure to heat; which-may be thin and light in weight and thus appropriate for use in high-grade shoes; whose use ensures the preservation of the smooth lines of the last without'bulging of the upper and which are thus applicable to plain-toe shoes; and which will yield, when pressed, but which return automatically to shape `when pressure is released.

Most of the materials-heretofore employed for stiffening shoe uppers require to be softened prior to lasting, as above described, in order that they may be conformed to the wood of the last, or else are so expensive as to be of limited utility.' A further object of the inventionis to provide a stiiener of permanently "resilient, yieldable character which does not require softening treatment prior to lasting in order that it may be conformed `to the last; which provides the desired degree of resilient stiffness in the completed shoe; .and which Aat theisame :time is so cheap as to make it readily available to manufacturers of `even the lower grades of shoe.

As the result of much experiment with the` latter object in particular in view, it has been discovered vthat stiiener material possessing all of the `above desirable characteristics maybe lmade from old automobile tires, Vblow-outy patches, etc., which, as is Well known,l consist of a plurality of -superposed plies each comprising a layer ofsubstantially parallel, independent, un-

woven cords embedded in a layer or layers of vulcanized rubber. Old tires are available in almost unlimited quantities and form a very cheap source of material. In preparing Vthe'stiiener in accordance with the present'invention, such a -tire may be separated into plies of'suitable thickness; each such ply comprising one or more layers of cordsand-one ormore layers of rubber, as desired, in Yaccordance with the intended use of thestiffener and the mode employed in separating the plies.4

Other' objects and advantages of the invention and a specic-mode of carrying it into eiect will be' pointed outin the-following more detailed description and by reference to theaccompanying drawing, wherein- Fig. 1 is a plan view of a toe stiiener blank j embodying the present invention, a part of the rubber-layer being broken away toshow the in- -terior construction; Fig. 2 is a'section on the line 2--2 oiFig. 1; Fig. 3'is'a section similar tof Fig. 2, but illustrating a slight modification; Y

fFig.-4-is a view similar to Fig. 1, but illustrating the elastically stretchable character of the Vmaterial;

l`Fig. 5 is a view similarto Fig. l, showing a toe stiffener blank so prepared that its constituent Y Vcords extend transversely of the blank;

Fig. 6 is a view similar toFig. 5, showing the -effects'of stretching the blank of Fig. 5;

Fig. '7 is a plan View, to small scale, showing a heel stiffener embodying the present invention; Fig.v 8-is a fragmentary perspective view, partly in section, showing a tire adapted to constitute .a source of material from which the improved stiifener may Abe made;

Fig. 9 is a View similar to Fig. 2, showing afurther-modification; and

Fig. 10 isa diagrammatic View illustrating a' vmethod of separating the tire fabric into plies.

Referring to the drawing, the numeral I 'des-Y ignates a `t'oe stiffener blank embodying the pres- Yent invention and 'useful in stiffening the-toe or Etip portion Vof the upper of aV shoe or other article interposed between and lembedded in layers 2 andY 4 /of vulcanized rubberor material having,

similar characteristics,-in particular resiliency and ability to withstand the effects of moisture and heat. As illustratedin Fig. 1, the cords 3 are` normally disposedV quite close together and extend substantially parallel to the front-to-rear axisof the stiffener blank, so that vin the lasted shoe these cords will run fromfront to rear. These cordsI will usually be twisted cords of cotton, each cord consisting of a plurality of spun yarns twisted together. Such a blank as that shown in Fig. 1 is capable of stretching substan-` tially in a transverse direction (as illustrated in Fig. k4) the cords 3 separating `more or less as the elastic rubber layers in which they areembedded. yield to the stretching force, but Ywhen this force is released the blank tends to resume its normal dimensions; Y

When such a blank is used as a stiifener in a n shoe, it may be introduced as usual between the Vliningan'dthe outer elements of the shoe upper prior yto lasting, but it requires noY preliminary treatment, before lasting, to Vsoften it or make it Y flexible, such as is commonly required inthe use of stiieners of 'more usual Vtypes'. During the lasting operation the stiiener is conformed vto the shapeof the toe portion of the last, and after lasting-fand after the last has been drawn from :the shoe, this shaped stifener blank, by reason of its inherent resiliency, adequately supports the tip portion of the shoe upper in its lasted form. If during the wear of the shoe the toev portion be crushed inwardly, the resilient character of the j stiffener-'immediately causes the upper to spring out again, and since the material of this stiffener is not readily aifectedV by moisture or such heat as a' shoe is ordinarily subjected to, it retains the 'upper material of theshoe in proper shape and condition throughout the life of the shoe.

While, as illustrated in Figs. 1 and 2, the flexible material, of which the 4stiener blank is madecomprises a single layer 3 of the parallel woven cords, with a layer of rubber at each side,

. it is contemplated that, as illustrated in Fig. .53,

the yblank may comprise but a single layer of rubber. Thus as Shown in this figure thematerial from Whichthe blank is cut consists of one layer of parallel cords 2a, and a singlelayer 4a of rubber, in which the layer of cords is` embedded.

It is to'be noted that inthe arrangement shown in Figs; 1, 2 and 3, vthe'material of the blank is reely extensible or stretchableV in a direction perpendicular to the axes of the cords 2, but is substantially inextensible in adirection parallel to the cords. In Figs. 5 and 6 a stiffener blank is shown com prising the rubber layers 2b and 4b and the interposed layer ofcords 3b, but in this instance the cords 3b, which areparallelto each other and unwoven, as in the previously described material, extend transversely of `the front-to-rearV axis of the stiffener blank. .This vblank can be extended or stretched'in a front-tofrear direction,-as indiv cated in Fig. 6, the. cords `3l-then being spaced more widely apart than in the normal arrangement, but when the stretching force is released the blank resumes its normal dimensions. Under some conditions it may be preferable to, employ a blank having the cords disposed as in Figs. 5 andv 6, rather than as shown in Figs.` 1 and. 4.

InFig. '7 a heel stiffener blank or counter mem- `ber 'I` is illustrated, V4s uch blank comprising the rubber layers 2c and 4c with the interposed layer Y ofY parallel cords 3C. Ask shown, thecords 3C extend parallel to the :shorter dimension of the .blank, but it is contemplated that theymay run parallel to the longer dimension of the blank or in any other way, if preferred. 1

As a matter of fact, many of .theadvantagesr of the invention are to be obtained regardless of made comprises a layer 2m of rubber, alayer 3m of parallel cords extending in a givenl direction,

` a layer 4m of rubber, al second layerm Vof vparallel cords (the cords of the latter layer running substantially perpendicular to the cords of the layer 3m) and a third layer Bmof rubber. l

The material used in making thestiener blanks above described is conveniently obtained from old automobile tires or blow-out pate-hes. A portion ofsuch a'tire is indicated diagrammatically at 8 in Fig. 8. Such tires are commonly built up of superposed layers of rubber and parallelcords, the arrangement being such, for example, as is indicated rin Fig. 8, wherein the cords I2 of one layer extend Vin a given direction,

the cords I3 of the next cord layer extend substantially perpendicular to thoseof the first layer; the cords YIII of the next successive cord layer the direction in which the cords extend in theV blank, and as illustrated, for example, in Fig. 9, it

extend parallel to those of the layery I2; then the cords I5 of the next cord layer extend parallel' to those of the layer I3, etc., it being understood that the layers of cords are embedded in interposed layersof vulcanized rubber.

At this ypoint it'may be mentioned that while vulcanized-rubberY and textile cords are the common material now used in tires for imparting the desired resiliency and wearing qualities to automobile tires, itis contemplated4 that the present invention is broadly inclusive of any materials havingthese general characteristics and such as may now Aor hereafter be employed Vin the manufacture of automobile tires or the like, and ythat when in the appended claims, reference is'made to rubber and cords, these terms are to be considered as broadly inclusive of equivalents. l

In making the stiffener blanks abovedescribed, such an automobile tire maybe cut into sections, and a suitable piece of thismaterial may then be properlyheld in a splittingl machine and divided into a plurality of plies, each suitable as a material or fabric from which to cut thestiifener blanks. Thus, as illustrated in Fig. 10, a block of' be lubricated by a stream of water) andthe knifev Y and thematerial arethen so relatively moved as to cause theknife to split preferably one of the rubber layers, for example, the layer |43, s o as to separate from the block of tire fabric a ply P comprising the rubber'layers: 2X and 4X and the interposed layer 3X of parallel cords. thus produced'would `be like ythe material shown in Fig. 2, and this ply may then be cut into blanks such as the blank I in any suitable manner, for

The ply ,Y I

example, by the use of dies in a dinking machine. I

Obviously, the splitting operation may be carried out so as to produce fabric .plies like that Vof Fig. 2, or like that of Figs. 3 or 9, respectively, or in any other suitable manner according to the use to which the ply material is to be put. Preferably the splitting should be so carried out as not substantially to injure the cord layer, so that the ply material may possess the maximum strength due to the presence of the textile fiber, it being noted that the textile material used in automobile tires is usually of a very high quality,

the spun yarns consisting of long staple cotton.

While it has been suggested that material from used automobile tires constitutes a very cheap and abundant source of fabric suitable for use in making the improved stifener blanks, it is to be understood that in its broader aspects the invention is not necessarily limited tomaterial from such a source, but that material having the desired characteristics may obviously be obtained from any suitable source, or made especially for the purpose if preferred. It is further to be understood that the invention is broadly inclusive of all equivalents either of materials or their relative arrangement, and which fall Within the scope of the appended claims.

I claim:

1. A shoe stiffener blank which is substantially inextensible in one direction but which is stretchable and permanently elastic in a direction sub` stantially at right angles thereto, said blank comprising a normally stretchable elastic layer and substantially parallel relatively inextensible cords united to the elastic layer, said cords opposing stretch of the blank in one direction but freely separating from each other when the blank is subjected to stretching stress in a direction transverse of the cords.

2. A shoe stiiener comprising a permanently elastic layer and a layer consisting of substantially parallel, unwoven, normally closely adjacent, flexible strands adherent to the elastic layer.

3. A shoe stiener comprising a layer of sub- Y 5. A shoe stiffener blank comprising a layer of substantially parallel, independent unWoven cords disposed in substantially the same plane, and a layer of moisture-resistant elastic material having the general characteristics of vulcanized rubber in Which said cords are at least partially embedded.

6. A permanently resilient shoe stiffener blank comprising vulcanized rubber and layers of substantially parallel cords embedded in the rubber, the parallel cords comprised in one layer extending in a different direction from the parallel cords comprised in the adjacent layer.

'7. That method of stifening a shoe upper which comprises separating an automobile tire into plies each comprising a layer of substantially parallel unvvoven and independent cords and at least one layer or normally elastic material in which sai-d cords are partially embedded,

cutting from such a ply a blank of the desired contour and dimensions, assembling said blank, without further treatment, with other parts of a shoe upper, and lasting the upper together With the assembled blank.

8. That method of stiffening a shoe upper which comprises separating an automobile tire into plies each comprising a layer of substantially parallel unvvoven and independent cords and at least one layer of normally elastic material in which said cords are partially embedded, cutting from such a ply a blank of the desired contour and dimensions, so assembling the blank, Without further treatment, With other parts of the shoe upper that the constituent cords of the blank lie substantially parallel to the longitudinal axis of the upper, and lasting the upper together with the assembled blank.

9. That method of stiffening a shoe upper l which comprises separating an automobile tire into plies each comprising at least one layer of substantially parallel unwoven and independent cords, and layers of vulcanized rubber, one at.

each side of the cord layer, cutting from said ply a blank of the desired contour and dimensions, assembling such blank with other parts of the shoe upper, and, Without further treatment of the stiffener blank, lasting the upper together with the assembled blank.

NICHOLAS W. MATHEY'. 

